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Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
On-line Process Analyzers -
Quo Vadis?
(about prima donnas, dinosaurs, etc.)
Peter van VuurenOptografTM Product Manager
SpectraSensors/Kaiser AnalyticsJan 20, 2011
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
TCO
$Measurement value$“Analyzer Credits” $Bottom-line Value$
Process Analysis Value Proposition
• Safety• Efficiency
(Control/Optimization)• Environmental
• Cost to Buy/Build/Install• Cost to Own
• Profit Center?
• Cost Center?
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
We treat our Analyzers nicely, with respect, TLC etc.
Picture Courtesy ExxonMobil ChemicalPicture Courtesy ExxonMobil Chemical
TCO Considerations TCO COnsiderations
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
A Lot of Infrastructure
(Brute Forcing the Installation)
A/C
Sample Conditioning
Systems
Sample Transport
Lines
AnalyzerShelter
Picture Courtesy ExxonMobil ChemicalPicture Courtesy ExxonMobil Chemical
TCO Considerations
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
Sample Conditioning Systems:
* Custom designed, engineered and built
* Poor standardization
Picture Courtesy ExxonMobil ChemicalPicture Courtesy ExxonMobil Chemical
TCO Considerations
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
Sample Conditioning Systems:
* Custom designed, engineered and built
* Lots of tubing/fittings
* Many man-hours designing/building it
* Lots of discrete components
Cost Issue – Irritates the Bean Counters
* Typically not Smart
(Smart = knowing if p,t,f of sample are
normal, i.e. validating representative
sample)
“Quality of Measurement Issue” -
Credibility of analysis
Picture Courtesy ExxonMobil Chemical
TCO Considerations
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
Analyzers treated like Prima Donnas
We change the environment to meet their needs
Picture Courtesy ExxonMobil ChemicalPicture Courtesy ExxonMobil Chemical
TCO Considerarations
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
Real Prima Donna Analyzer Prima Donna
His/her Own Dressing Room
+ a big star on the door
Same
Star on the outside door missing
All the necessary facilities to make the room meet all his/her needs:Air conditioning
Air conditioning, own instrument air, hazardous area adaptation etc., vent lines, headers
His/her own bar (food, drinks etc.) Its own sample at the right pressure and temp
Has his/her own entourage:Hairdresser, pedicurist, manicurist etc.
Technicians, analyzer engineers etc.
An Analyzer Prima Donna?
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
Number
K USD
each
K USD
total PCT
Gas chromatographs 50 30 1500 38
Other analysers 75 10 750
Sample systems 125 10 1250 30
Sample transport 125 5 625
Analyser houses 8 200 1600 27
Data system 1 150 150 3
Installation costs 1 125 125 2
TOTAL 6000
J.J. Gunnell and P. van Vuuren, “PROCESS ANALYTICAL SYSTEMS: A VISION FOR THE FUTURE”Plenary Session Paper, IFPAC2000, Las Vegas, NV
Lifetime 15 years
Number of equivalent analysers 250
Equivalent analyser per technician 50
Cost of spares per equivalent analyser / yr 1200 USD
Number USD / hr K USD / yr
Technician 5 30 300
Engineer 1 50 100
Spares 300
Consumables 100
TOTAL / yr 800
TOTAL / life 12000
To Buy/Build/Install
To Own
Cost to Build/Install/Own – Major Greenfield Project
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
$ = X2
• Analyzer $/ SpareParts
• Sampling Systems
• Shelters/Panels
• Data System
• Sample Tap / Transport Lines
• Utilities (IA, Carrier Gases etc.)
• Power
• Cabling
• Shelters/Panels
• Hookups :Utilities, Power, Cabling, Sampling Systems
• Start-up &Commissioning
• EQAT (Manpower)
• Consumables* Standards* Support Gases
• Spare Parts
• Off-line TimeMissed Opportunity
• Process UpsetLoss of Production
Total Cost Of Ownership – A More Detailed Look
Cost to Buy/Build &Install Cost to Own/Operate
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
"When men got structural steel, they did not use
it to build steel copies of wooden bridges."
Ayn Rand. Atlas Shrugged. 1957.
What to do?
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
Or as Rob Would Say
"When analyzer men got NeSSI they did not use
it to build duplicates of legacy
sampling systems”
Rob Dubois
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
Programmable Substrate Heater
Ethernet LAN
F,T
Sensor/ActuatorManager (SAM)
IS NeSSI bus
Auxiliary Heating/Cooling
Flow Channel SubstrateT
T
DCS o&muser
PDA
P
GP Area
Field –Classified Area
V
Micro- Climate enclosure
NeSSI = Sampling & Communications Platform
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
Field LAN
Pro
ce
ss S
tre
am
SS
AN
DCS
o&muser
GP AreaField –Classified Area(Typically ZONE2)
Analyzer House
Connecting the DOTS
AN
Instrument Room
Analyzer Shop
Control Room
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
Field LAN
Pro
ce
ss S
tre
am
SS
DCS
o&muser
GP AreaField –Classified Area(Typically ZONE2)
Analyzer House
Moving the DOTS
Instrument Room
Analyzer Shop
Control Room
AN
AN
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
Pro
ce
ss S
tre
am
DCS
o&muser
GP Area
Field –Classified Area(Typically ZONE1)
Enabled by:
e.g. NeSSI PlatformMiniaturizationIS Design
ANFiber
RAMANNeSSI
Control Room
Analyzer Shop
NDIR/RAMAN
Enabling Topographical Changes: FUTURE
AN
AN NDIR/RAMAN
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
Intensive/Major Infrastructure Requirements
Minimal Infrastructure Requirements
Micro-House@ Sampling Point
NeSSI PlatformIntrinsically SafeMicro-Analyzers
Fiber-Optic probes
Macro-Analyzers
Macro-House
Legacy SS
Total Cost of Ownership - Gen III Vision
Courtesy of Dow Chemical, Freeport, Texas
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
TCO
$Measurement value$“Analyzer Credits”
TCO
Process Analysis Value Proposition - TCO Optimized
$Bottom-line Value$
$Bottom-line Value$
Perception of Process Analytics: Profit Center
Cost
PROFIT
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
If we look down the road:
What should the attributes of the ideal next generation analyzer system be?
Vision for the Future
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
Sample probe
• In the pipe or at the pipe
• High temp and flows
• Filtering of particulates
• Removal or rejection of condensables
• No or limited sample removal (in/ex situ sampling)
Sample handling
• At line or near line pressure
• Minimal sample conditioning
• No sample transport
• No sample return required
• Ports for calibration/validation
• Pressure and Temperature (and Flow Measurement)
Attributes of the ideal next generation analyzer system?
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
Analyzer sensor/controller
• Poles to tropics operation
• Does not require an analyzer shelter
• Intrinsically safe or flame proof (miniature)
• No or few moving parts (inherently reliable)
Communications• With DCS
• Serial data links OPC, Modbus TCP/IP
• Future wireless
• With maintenance LAN
• Separate and firewalled from DCS and other plant devices & LANS
• Diagnostics/history/setup
• Remote access/operations (off-site maintenance)
• Wired or Wireless
Attributes of the ideal next generation analyzer system?
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
• We must change if we want to avoid becoming a dinosaur technology.
• It’s now time to move ahead with Generation III
– A scorecard to set the stage for on-line methodologies is underway.
– microAnalytical is our future - now
Tutorial Conclusion
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
Thank You
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
Micro-analytics Design Requirements
• Understand the NeSSI Platform Concept (Enabler)* Provides a Standardized Micro-Infrastructure Environment
for Deploying micro-analytical sensors/Analyzers* At the same time, allows for IP protection
• IS has to be designed in up front
• Design for temperature accommodation/correction* NeSSI platform can be installed anywhere (Zone 0/1/2 GP)
– no costly purge systems
• Design for validation of results (Good Housekeeping Seal)* Use all the analytical process information for validation
• Design for no or little consumables
• Design for mecahnical simplicity – no or few moving parts
• Design for extensive but smart diagnostics
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
The Case for a Micro-Analytics Initiative at CPAC
• The NeSSI slogan is apropos: “The best way to predict thefuture is to create it”
• Clearing House for Micro-analytical Design requirementsbased on the NeSSI platform* Developments of new technology typically done in research center
or academic environments* Design guidelines will accelerate product to market time* Can position the USA again as a leader in innovative analytical
product development and commercialization
• Clearing House for Industrial Needs in search of a (micro)-analytical solution
• Provide a forum for facilitation/education/coordination* Annual conference on Micro-analytics (complimentary to Summer
Institute)
• CPAC knows how to drive and manage an initiative
• Open the door to alternative funding sources?
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
Acknowledgements
• All the Believers (all of you and many others)
• My ex-colleagues at ExxonMobil
• CPAC (adopted NeSSI as a new IURC “business model”)
• Special Tribute/Thank You to Rob Dubois
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
Analytical Clusters Concept > Going Micro All the Way
Pictures Courtesy of Dow Chemical Freeport, TX
Analytical Cluster = A Process Stream Requiring Multiple Analyte Measurements
Examples: On-line Propylene CertificationCEMS (Stack Analysis)Cooling WaterWaste Water Treatment/Effluents
Byline Analytical Cluster = Multiple Analyte Measurements done on a Single NeSSI Platform
Macro-House Micro-House
Macro-Analyzers Micro-Analyzers
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
Programmable Substrate Heater
Ethernet LAN
AnalyzerController
V
A
P F
SAM
NeSSI bus
Auxiliary Heating/Cooling
SubstrateT
T
Standard
Sampling
Interface
dcs o&muser
Standard
Connectivity
Interface
NeSSI “Sandwich/Rail” Platform Concept
next
PDA
Development
Focus can be
on Sensors !
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
TCO
$Measurement value$“Analyzer Credits”
Process Analysis Value Proposition - TCO Optimized
$Bottom-line Value$
TCO $Bottom-line Value$
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
Number
K USD
each
K USD
total PCT
Gas chromatographs 50 30 1500 38
Other analysers 75 10 750
Sample systems 125 10 1250 30
Sample transport 125 5 625
Analyser houses 8 200 1600 27
Data system 1 150 150 3
Installation costs 1 125 125 2
TOTAL 6000
J.J. Gunnell and P. van Vuuren, “PROCESS ANALYTICAL SYSTEMS: A VISION FOR THE FUTURE”Plenary Session Paper, IFPAC2000, Las Vegas, NV
Lifetime 15 years
Number of equivalent analysers 250
Equivalent analyser per technician 50
Cost of spares per equivalent analyser / yr 1200 USD
Number USD / hr K USD / yr
Technician 5 30 300
Engineer 1 50 100
Spares 300
Consumables 100
TOTAL / yr 800
TOTAL / life 12000
To Build/Install
To Own
Cost to Build/Install/Own – Major Greenfield Project
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
• Analyzer $/ SpareParts
• Sampling Systems
• Shelters/Panels
• Data System
• Sample Tap / Transport Lines
• Utilities (IA, Carrier Gases etc.)
• Power
• Cabling
• Shelters/Panels
• Hookups :Utilities, Power, Cabling, Sampling Systems
• Start-up &Commissioning
• EQAT (Manpower)
• Consumables* Standards* Support Gases
• Spare Parts
• Off-line TimeMissed Opportunity
• Process UpsetLoss of Production
Total Cost Of Ownership – A More Detailed Look
Cost to Buy Cost to Own/Operate
Rational/Big Picture
Zone
Rational/Big Picture
View
Sticker Shock Zone
Sticker Shock Zone
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
Topic
+
TCO
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
TCO
$Measurement value$“Analyzer Credits” $Bottom-line Value$
Process Analysis Value Proposition
• Safety• Efficiency• Environmental
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
What is Wrong with these Pictures
A Lot of Infrastructure
(Brute Forcing the Installation)
A/C
Sample Conditioning
Systems
Sample Transport
Lines
AnalyzerShelter
Picture Courtesy ExxonMobil ChemicalPicture Courtesy ExxonMobil Chemical
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
$ = X2
• Analyzer $/ SpareParts
• Sampling Systems
• Shelters/Panels
• Data System
• Sample Tap / Transport Lines
• Utilities (IA, Carrier Gases etc.)
• Power
• Cabling
• Shelters/Panels
• Hookups :Utilities, Power, Cabling, Sampling Systems
• Start-up &Commissioning
• EQAT (Manpower)
• Consumables* Standards* Support Gases
• Spare Parts
• Off-line TimeMissed Opportunity
• Process UpsetLoss of Production
Total Cost Of Ownership – A More Detailed Look
Cost to Buy Cost to Own/Operate
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
LAN
Pro
ce
ss S
tre
am
SS
AN
DCS
o&muser
GP AreaField –Classified Area(Typically ZONE2)
Analyzer House
Process Analytics Installation – Existing Analyzer Replacement
4 – 20 mA
Modbus
Replace Analyzer with RAMAN/SSS(maximize existing infrastructure)
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
Optography
“Chromatography” with Laser Light
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
Cost to Build/Install/Own – Major Greenfield Project
Number
K USD
each
K USD
total PCT
Gas chromatographs 50 30 1500 38
Other analysers 75 10 750
Sample systems 125 10 1250 30
Sample transport 125 5 625
Analyser houses 8 200 1600 27
Data system 1 150 150 3
Installation costs 1 125 125 2
TOTAL 6000
J.J. Gunnell and P. van Vuuren, “PROCESS ANALYTICAL SYSTEMS: A VISION FOR THE FUTURE”Plenary Session Paper, IFPAC2000, Las Vegas, NV
Lifetime 15 years
Number of equivalent analysers 250
Equivalent analyser per technician 50
Cost of spares per equivalent analyser / yr 1200 USD
Number USD / hr K USD / yr
Technician 5 30 300
Engineer 1 50 100
Spares 300
Consumables 100
TOTAL / yr 800
TOTAL / life 12000
To Build/Install
To Own
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
NeSSI Topography
Field LAN
Pro
ce
ss S
tre
am
SS
AN
AN
DCS
o&muser
GP AreaField –Classified Area(Typically ZONE2)
Analyzer House
XX
X
X
X
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
Intensive/Major Infrastructure Requirements
Minimal Infrastructure Requirements
Micro-House@ Sampling Point
NeSSI PlatformIntrinsically SafeMicro-Analyzers
Fiber-Optic probes
Macro-Analyzers
Macro-House
Legacy SS
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
• EQAT (Manpower)
• Consumables* Standards* Support Gases
• Spare Parts
• Off-line TimeMissed Opportunity
• Process UpsetLoss of Production
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
Programmable Substrate Heater
Fiber-Optic Sensors with NeSSI as Enabler
Ethernet LAN
F,T
Sensor/ActuatorManager (SAM)
IS NeSSI bus
Auxiliary Heating/Cooling
Flow Channel SubstrateT
T
DCS o&muser
PDA
P
GP Area
Field –Classified Area
VO2
R
Micro- Climate enclosure
TDL, CRDS,
NIR…
RAMAN
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
Process Analytical Infrastructure Topography
Field LAN
Pro
ce
ss S
tre
am
SS
AN
DCS
o&muser
GP AreaField –Classified Area(Typically ZONE2)
Analyzer House
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
Field LAN
Pro
ce
ss S
tre
am
AN
DCS
o&muser
GP Area
Field –Classified Area(Typically ZONE2)
Analyzer House
Field –Classified Area(Typically ZONE2)
Micro-Climate Enclosure
Ne S SI
SAM
Process Analytical Infrastructure Topography
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
Field LAN
Pro
ce
ss S
tre
am
SS
AN
DCS
o&muser
GP AreaField –Classified Area(Typically ZONE2)
Analyzer House
Process Analytical Infrastructure Topography
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
NeSSI Enabled Spectroscopy Process Analytics Topography
Pro
ce
ss S
tre
am
DCS
o&muser
GP Area
Field –Classified Area(Typically ZONE2)
Micro-Climate Enclosure
AN
AN
FiberRAMAN
NIRFiber
Ne S SI
SAM
Control Room
Instrument Room
Analyzer Shop
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
• Phase 1 (On-Going)Implement Intrinsically Safe NeSSI where appropriate
• Phase II (Ready for Validation)Utilize NeSSI as a Platform for Fiber-Optic Sensorspreferably at the Sampling Point (By-line Mode)
• Phase IIIPromote/Apply Micro-Analytical Sensors in By-Line Mode
A TCO Optimization Strategy
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
Programmable Substrate Heater
NeSSI & Next Generation Micro Analyzers
Ethernet LAN
F,T
Sensor/ActuatorManager (SAM)
IS NeSSI bus
Auxiliary Heating/Cooling
Flow Channel SubstrateT
T
DCS o&muser
PDA
P
GP Area
Field –Classified Area
V
Micro- Climate enclosure
Micro- GasAnalyzer(UV, MIR, MS, GC, …
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
Topics for RAMAN Gas Analysis or Optical Chromatography
1. Role of Process Analytical Measurements
2. RAMAN Phenomenon
3. Optograms/Applications
4. Performance
5. Optography vs. Chromatography
6. Hardware
7. “Greening” of the User Interface
8. TCO Considerations
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
Role of Process Analysis
1. Enable Safe Operations
2. Implement Mandated Environmental Monitoring
3. Efficiency (Control & Optimization)
* Quality of Data (Data Validation)
* Reliability of Data (98+ Service Factor)
4. Total Cost of Ownership
* Cost to Buy/Build/Install
* Cost to Own (Manpower, Operating Costs)
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
A Lot of Infrastructure
(Brute Forcing the Installation)
A/C
Sample Conditioning
Systems
Sample Transport
Lines
AnalyzerShelter
Picture Courtesy ExxonMobil Chemical
TCO Considerations
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
• Analyzer $/ SpareParts
• Sampling Systems
• Shelters/Panels
• Data System
• Sample Tap / Transport Lines
• Utilities (IA, Carrier Gases etc.)
• Power
• Cabling
• Shelters/Panels
• Hookups :Utilities, Power, Cabling, Sampling Systems
• Start-up &Commissioning
• EQAT (Manpower)
• Consumables* Standards* Support Gases
• Spare Parts
• Off-line TimeMissed Opportunity
• Process UpsetLoss of Production
TCO Benefits of RAMAN/Smart Sampling System
TCO Benefits of RAMAN/Smart Sampling System:• Reliability
* Push Validation down to Sampling System Level(75+% Analyzer Problems > Sampling System)
* More Reliable Analyzer Hardware
• Reduce Sample System Hardware Costs* Minimize Sample Transport Costs
• Reduce Shelter Requirements * Remote probes
• No Consumables
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
Pro
ce
ss S
tre
am
DCS
o&muser
GP Area
Field –Classified Area(Typically ZONE2)
Micro-Climate Enclosure
AN
AN
FiberRAMAN
NIRFiber
Cell/SSS
SAM
Control Room
Instrument Room
Analyzer Shop
NDIR/RAMAN
NIR Photometers
Enabling Topographical Changes: New/Greenfield Projects
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
Field LAN
Pro
ce
ss S
tre
am
SS
AN
DCS
o&muser
GP AreaField –Classified Area(Typically ZONE2)
Analyzer House
AN
Instrument Room
Analyzer Shop
Control Room
Process Analytics Installation – New/Greenfields Projects
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
LAN
Pro
ce
ss S
tre
am
SS
AN
DCS
o&muser
GP AreaField –Classified Area(Typically ZONE2)
Analyzer House
Simplified Topographical Diagram of a Process Analytics installation
4 – 20 mA
Modbus
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
• Analyzer $/ SpareParts
• Sampling Systems
• Shelters/Panels
• Data System
• Sample Tap / Transport Lines
• Utilities (IA, Carrier Gases etc.)
• Power
• Cabling
• Shelters/Panels
• Hookups :Utilities, Power, Cabling, Sampling Systems
• Start-up &Commissioning
• EQAT (Manpower)
• Consumables* Standards* Support Gases
• Spare Parts
• Off-line TimeMissed Opportunity
• Process UpsetLoss of Production
Total Cost Of Ownership – A More Detailed Look
Cost to Buy Cost to Own/Operate
Rational/Big Picture
Zone
Rational/Big Picture
View
Sticker Shock Zone
Sticker Shock Zone
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
Field LAN
Pro
ce
ss S
tre
am
SS
DCS
o&muser
GP AreaField –Classified Area(Typically ZONE2)
Analyzer House
Connecting the DOTS
Instrument Room
Analyzer Shop
Control Room
AN
AN
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
Spectroscopic Options
On-line RAMAN/NDIR Spectroscopy0.5% - 100%
• Trace Level TDLAS/DA1% - 0.1 PPM
• UltraTrace Spectroscopy as PPBMeasurement Alternative100 PPB - 1 PPB
Spectroscopy as a Vehicle for TCO Optimization
Why Spectroscopy?
Inherently reliable technique(no of few moving parts)
• No or minimal consumables(no carrier gases, instrument air)
• Remote SamplingUncouple the sampling interface from the analyzer proper
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
• Analyzer $/ SpareParts
• Sampling Systems
• Shelters/Panels
• Data System
• Sample Tap / Transport Lines
• Utilities (IA, Carrier Gases etc.)
• Power
• Cabling
• Shelters/Panels
• Hookups :Utilities, Power, Cabling, Sampling Systems
• Start-up &Commissioning
• EQAT (Manpower)
• Consumables* Standards* Support Gases
• Spare Parts
• Off-line TimeMissed Opportunity
• Process UpsetLoss of Production
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
• Analyzer $/ SpareParts
• Sampling Systems
• Shelters/Panels
• Data System
• Sample Tap / Transport Lines
• Utilities (IA, Carrier Gases etc.)
• Power
• Cabling
• Shelters/Panels
• Hookups :Utilities, Power, Cabling, Sampling Systems
• Start-up &Commissioning
• EQAT (Manpower)
• Consumables* Standards* Support Gases
• Spare Parts
• Off-line TimeMissed Opportunity
• Process UpsetLoss of Production
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
Pro
ce
ss S
tre
am
DCS
o&muser
GP Area
Field –Classified Area(Typically ZONE2)
Micro-Climate Enclosure
AN
AN
FiberRAMAN
NIRFiber
Ne S SI
SAM
Control Room
Instrument Room
Analyzer Shop
P
NeSSI Enabled Spectroscopy/MA Process Analytics Topography
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
• Analyzer $/ SpareParts
• Sampling Systems
• Shelters/Panels
• Data System
• Sample Tap / Transport Lines
• Utilities (IA, Carrier Gases etc.)
• Power
• Cabling
• Shelters/Panels
• Hookups :Utilities, Power, Cabling, Sampling Systems
• Start-up &Commissioning
• EQAT (Manpower)
• Consumables* Standards* Support Gases
• Spare Parts
• Off-line TimeMissed Opportunity
• Process UpsetLoss of Production
TCO Benefits of RAMAN/Smart Sampling System
TCO Benefits of RAMAN/Smart Sampling System:• Reliability
* Push Validation down to Sampling System Level(75+% Analyzer Problems > Sampling System)
* More Reliable Analyzer Hardware
• Reduce Sample System Hardware Costs* Minimize Sample Transport Costs
• Reduce Shelter Requirements * Remote probes
• No Consumables
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
Today’s Process Analytics Topographical View = PAT
Field LAN
Pro
ce
ss S
tre
am
SS
AN
DCS
o&muser
GP AreaField –Classified Area(Typically ZONE2)
Analyzer House
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
• Analyzer $/ SpareParts
• Sampling Systems
• Shelters/Panels
• Data System
• Sample Tap / Transport Lines
• Utilities (IA, Carrier Gases etc.)
• Power
• Cabling
• Shelters/Panels
• Hookups :Utilities, Power, Cabling, Sampling Systems
• Start-up &Commissioning
• EQAT (Manpower)
• Consumables* Standards* Support Gases
• Spare Parts
• Off-line TimeMissed Opportunity
• Process UpsetLoss of Production
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
Intensive/Major Infrastructure Requirements
Minimal Infrastructure Requirements
Macro-Analyzers
Macro-House
Legacy SS
Total Cost of Ownership - Gen III Vision
Courtesy of Dow Chemical, Freeport, Texas
• EQAT (Manpower)
• Consumables* Standards* Support Gases
• Spare Parts
• Off-line TimeMissed Opportunity
• Process UpsetLoss of Production
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
Sample Handling:
• At line or close to line pressure• Minimal Sample Conditioning• No sample transport• No sample return required• Ports for calibration/validation• Pressure and Temperature (and Flow
Measurement)
Sample Handling
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
Analyzer Sensor/Controller:
• Poles to tropics• Does not require an analyzer shelter• Intrinsically safe• No moving parts (inherently reliable)
Analyzer Sensor/Controller
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
Sampling Probe:
• In the pipe or at the pipe• High temp and flows• Filtering of particulates• Removal of condensables• No sample take-off
(in/ex situ sampling)
Probe
Process Analytics - Quo Vadis? IFPAC Conference : Jan20,2011, Baltimore
1. Communications to DCS
• Serial data links OPC, Modbus TCIP• Future compatibility with wireless
2. Diagnostic LAN
• Separate and Firewalled from DCS and other plant devices/LANS
• Virtual Interface• Full diagnostics/history• Remote access/operations (off-site
maintenance)
Communications